Flashing base with adjustable cant

ABSTRACT

Modular sections of a flashing base, having a cant adjustably attached thereto, may be made either in standard sizes or to order and shipped to site in knockdown and disassembled form. On site, the parts may be assembled and erected in place. The cant may then be moved relative to the deck line to cause the cant to rest upon the deck. Thereafter, roofing felt or similar material may be brought up from the approximately horizontal plane of the deck to the cant and flashing base for a distance of eight inches or more above the deck.

[ 1 May 28, 1974 FLASHING BASE WITH ADJUSTABLE CANT [75] Inventor: Raymond W. Resech, La Grange Park, Ill.

[73] Assignee: Pate Manufacturing Company,

Broadview, ll].

[22] Filed: June 1, 1973 [21] Appl. No.: 366,195

Related US. Application Data [62] Division of Ser. No. 246,565, April 24, 1972.

[52] US. Cl. 52/741, 52/745 [51] Int. Cl E04d 13/14 [58] Field of Search 52/58, 60, 96, 94, 200,

[56] References Cited UNITED STATES PATENTS 1,396,732 11/1921 Cramer.... ..52/60 3,216,161 11/1965 Forsman 52/219 X 3,363,369 1/1968 Miller 3,522,686 8/1970 Gordon et a1 52/745 Primary ExaminerPrice C. Faw, Jr. Attorney, Agent, or Firm-Alter Weiss Whitesel &

Laff

[ 57] ABSTRACT Modular sections of a flashing base, having a cant adjustably attached thereto, may be made either in standard sizes or to order and shipped to site in knockdown and disassembled form. On site, the parts may be assembled and erected in place. The cant may then be moved relative to the deck line to cause the cant to rest upon the deck. Thereafter, roofing felt or similar material may be brought up from the approximately horizontal plane of the deck to the cant and flashing base for a distance of eight inches or more above the deck.

4 Claims, 12 Drawing Figures FATENTEUMAY28 ISM 3,812,634 sum 2 BF 2 9 WALL DECK TOP CANT I FLASHING BASE NAI LER STRIP 99 i F FIGS 96 ROOF CONSTRUCTION 1 T INSULATION PITCHED FOR DRAINAGE COUNTER FLASH! NG 9. WOOD 7 I00 I FLASHING BASE WITH ADJUSTABLE CANT This is a division, of application Ser. No. 246,565, filed Apr. 24, 1972.

This invention relates to flashing bases for building roofs and, more particularly, to flashing bases which may be manufactured, shipped in a knockdown state and, thereafter, assembled on site.

Usually, a flashing base is viewed as a construction item for terminating roofing material by raising it to a level which is at least eight inches above the level of the roof deck. These flashing bases (sometimes called curbs) have vertical planes and the roof decks provide approximately horizontal planes. A'plate (called a cant)v set at a slanting plane at least partly fills the root of the angle between these .vertical and horizontal planes. The cant thus provides two approximately 45 angular bends which enable the roofing material to gradually change directions from the horizontal to the vertical and to eliminate an otherwise 90 angle bend which would cause cracks and roof leaks.

Heretofore, it has been common practice to make the entire curb, including the cant, as a custom designed and built unit. Thus, each manufacturer has been obliged to provide a great variety of different sizes, shapes, and types of curbs. All open seams on each curb are usually welded. Thereafter, the assembled unit is shipped to a building site. The resulting structure is heavy, large, and awkward to handle. It is expensive to ship. Truckers do not want to carry it since sharp edges damage truck interiors. On site, the structure often is too large and unwieldy to be conveniently carried upstairs. Therefore, a crane has sometimes been required to hoist the structure up the outside of the building to the roof. All of this special handling and shipping has caused curbs to have a high cost, as compared to the cost of other structural material.

Sometimes, the flashing base provides means for elevating the roofing material along a parapet wall. Sometimes it is more complicated. For example, when it is necessary to mount an air-conditioner on a roof, a flashing base frame is placed on the roof to form a pedestal, and the air-conditioner rests upon it. To provide the flashing base pedestal and accomplish the weather proofing, it is common practice to build sheet metal boxes which either provide or surround the leg or other structure attached to or resting upon the roof. Many other types of structure, such as vents, skylights, and the like, are mounted in a similar manner.

Even when the size and shapes of the flashing base are made to order, there are a number of problems which tend to defeat successful factory construction. For example, a roof is often given a non-standard pitch so that water will run off, and the pitch varies from an anticipated angle according to a workmans precision or lack of precision. Therefore, the base cannot be made with a horizontal cant. If the flashing base is precisely made with exactly the proper pitch, the cant will not necessarily fit the intended roof because it is not that precise. Moreover, assuming that the workman could always .make a perfect roof, many problems would still remain because roof structures change from job to job and even on the same job. To solve these problems, the manufacturer must custom make and coordinate almost every piece part or flashing base sent to any given job.

One solution would appear to be to complete the roof and then to set the flashing base on top of the roofing material. Here, however, the natural heating and cooling throughout the years, a grinding in of roofing material, and vibrations and the like, almost certainly will lead to leaking. Thus, it is apparent that the flashing base should be attached directly to the roof, with the cant resting on top of the deck of the roof, and that the roofing material should be brought up over the cant. However, even this simple solution raises more problems since different roofing specifications call for the emplacement of different materials between the roof and the top of the deck. The thickness and the nature of these materials vary greatly. Accordingly, there is no standard and there is a great variation indistance between the bottom of the flashing base attached to the roof and the bottom of the cant resting on top of the deck.

Accordingly, an object of the invention is to provide new and improved curbs. In this connection, an object is to provide knock down flashing curbs which fit all needs. More particularly, an object is to provide a curb for all roof openings with all sizes coordinated.

An object is to provide a single design which may be adapted to fit all manufacturers skylights, roof exhausters, vents, intakes, smoke hatches, flues, stacks, etc., and to provide uniform curb construction with watertight design, in a simple manner, for all roof pitches and types of construction.

Still another object is to save shipping costs by reducing the volume of space required to ship flashing curbs.

In keeping with an aspect of the invention, these and other objects are accomplished by providing modular flashing base sections which may be made either in standard sizes or to order, and shipped to the site in a disassembled form. In the factory, the cant is movably attached to the vertical flashing base wall. Therefore, when the flashing base is installed in the field, the cant may be moved to fit tightly against the deck. Then, the roofing material may be brought up to cover over the cant and the flashing base to form a waterproof seal.

A preferred embodiment of the invention may be understood best from a study of the following specification and the attached drawings wherein:

FIG. 1 shows, in perspective, and partly in cross section, a conventional curb construction;

FIG. 2A is a plan view of an exemplary sheet metal blank used to make the flashing base;

FIG. 2B is an end elevation showing an exemplary cross-section of the blank of FIG. 2A after it is folded;

FIG. 3 shows, in perspective, an exemplary corner joint of the inventive flashing base;

FIG. 4 is a rear perspective view of the cant piece used to fill the valley between the vertical flashing base wall and the approximately horizontal deck;

FIG. 5 is an end elevation view of the cant of FIG. 4;

FIGS. 6A-C are perspective views of alternative I FIG. 9 is a vertical cross-section taken along line 9-9 of FIG. 8.v

The conventional flashing curb 10 is exemplified in FIG. 1. It may be used to support any suitable objects, such as an air-conditioner, a skylight, vent, or the like, for example. The curb 10 may also be adapted to fit along an entire parapet wall at the perimeter of the roof. 8

The elements of the flashing curb shown at 10 are wooden nailer strips 13, a rigid insulator board (such as l /inch fiberglass) 14,.roofing felt 15,,and sheet metal 16. The insulator board prevents condensation of moisture on the inside of the cold sheet metal, and it has some sound absorption qualities to muffle the sound of the air-conditioner or fan. The sheet metal includes a vertical plane 17, a horizontal plane '18, and a cant plate 19 which fills the valley between the horizontal and vertical planes. The nailer strip provides an anchor print for the roofing felt. The horizontal plate 18 is attached to the roof. Then the roofing felt is brought up from the roof, over the cant l9, and attached to the nailer strip 13 above the vertical plate 17. The cant 19 thus provides a gradual bend which enables the roof to have smooth flowing lines. The prior art has generally taught that the entire curb 10 should be prefabricated in a factory, welded together, and shipped as a unit to the building site.

In keeping with an aspectof the invention, sheet metal stock is sheared, cut or otherwise formed in any desired length, somewhat in the form of the blank in FIG. 2. The blank may include a number of panels forming a main wall2l, a top wall 22, tab. 23, top base plate 24, a bottom base plate 25 and a tab 26. These panels are separated by foldlines 27-31. The blank is folded along these lines to form somewhat box-like members 32, 33 having a generally C-shaped crosssection, as shown in FIGS. 2B and 3. Suitable insulation, such as fiberglass insulation board 34, may be placed inside the channel of curb part members 32, 33. As shown in FIG. 2B, the lower panel or plate 25 may be partially formed to an open position. The insulation board 34 may be fitted in place. Then the panel member 25 may be further formed to the closed position, where the insulation board 34 is captured.

The top base plate 24 has a tab 36 on each end of the curb part members 32, 33, which tabs are mitered to fit against each other. On the top wall 22, one end of the channel is notched at 37 to provide a butt joint between the curb part members.

The main wall 2l-on curb part member 32 terminates in a plurality of tabs 40-43, which may be folded over to project perpendicularly from wall 21. Each tab is here shown as having a semi-pierced fingernail detent 44 formed therein. The opposite member 33 has a number of mating slots 45-48 formed therein. The dimensions are such that when the tabs 40-43 are pressed into the slots 45-48, the fingernail detents 44 snap into position in the slots and lock the two curb part members 32, 33 together. Thus, it should be apparent that a plurality of the curb part members 32, 33 may have any suitable length and be assembled into any suitable form, preferably square or rectangular.

FIGS. 1A and 3 show preferred tabs and detents for interconnecting the curb part members 32, 33. However, it should be understood that any other suitable arrangement may also be used. For example, FIG. 6A shows a plurality of interlocking and mating tabs 4 formed on the two curb part members 32A, 33A. Hence, it should be apparent that the two curb part members 32A, 33A may be joined by hooking the downtumed tabs 50-52 over the upturned tabs 53-55, respectively. FIG. 6B shows two partly formed seams 56, 57 on the curb parts members 328 and 33B. These seams may be slid together and then peened in place, thereby forming a double folded seam. FIG. 6C shows somewhat cylindrical members on the curb parts members 32C and 33C. The cylinders are vertically displaced with respect to each other to come together somewhat as the cylindrical bearings of a hinge. A suitable hinge pin.63 may then be slipped in place through the cylindrical members to complete the hinged connection.

Regardless of which of these or other methods is used for an on site assembly of the curb part members, the principle is that one unassisted workman should be able to put the units together. No special tools are required.

No multiplicity of small parts, screws, rivets, or the like,

are required either.

Two or more vertical guide members are attached, (as by spot welding, for example) onto the main wall sections 21 of each of the curb part members 32, 33. Each guide member has a generally T-shaped slot 71 therein, with an enlargement 72 at the top and a vertically disposed adjustment slot communicatingly dependent therefrom. These guide members are provided at each end of the curb part members 32, 33 and at as many intermediate locations as may be required by the strength and length of the material.

The cant member (FIGS. 4 and 5) comprises a somewhat V-shaped sheet of metal, preferably having vertically, aligned flanges 81, 82 at the open ends of the V-shape. The cant 80 may, have complementary miter cut. ends so that adjacent sections come together with a miter fit, as at 84, FIG. I.

The flanges 81, 82 includes an offset vertical fold, thereby providing a seat space 86. A bracket plate 87 has a pair of horizontally disposed adjustment slots 88, 89 formed therein. This bracket plate is inserted in the seat area 86 on the flanges 81, 82, respectively. Then, it is attached to cant 80 in any suitable manner, as by spot welding, at 90. One of these plate brackets 87 is provided adjacent each of the guide ways 70, when the cant 80 is held adjacent a curb part member 32 or 33.

A pair of fasteners 91, 92 are slidably captured in these slots 88, 89. Initially, each of these fasteners may have the contours generally shown in FIG. 7. More particularly, the fastener 91 has a cylindrical shank 93 with an enlarged head 94 on one end and a rivet-like portion 95 on the other end. The rivet portion 95 may be swagged or otherwise shaped and adapted to slidably secure the fasteners in the slots 88, 89. The cylindrical shank 93 is shaped and proportioned to slide in the horizontal slots 88, 89 and the vertical slot 71. Thus, the

head 94 may be slipped through the enlarged slot areato enable the cant to be moved on the curb part members 32, 33, while being frictionally held securely in place. Moreover, the thickness of brackets 70, 87 and the length of shaft 93 are interrelated to hold the cant 80 as close as practical to the main walls 21.

The principles of the invention are illustrated in FIGS. 8 and 9. More particularly, the roof 96 may be made of any suitable construction. The flashing base is attached to the roof so that the main wall panel 21 rises directly from the roof itself, and, in this exemplary case, is attached also to a parapet wall 97. An insulation material 98, placed over the roof 96, is tapered in this particular drawing in order to illustrate one of the many reasons why the cant should be adjustable. This taper gives the roof a drainage pitch which is distinctly 7 different from the supporting structure of the roof itself. I

The cant 80 is pressed downwardly to rest firmly, with a good fit, against the upper surface of the insulation 98. For this purpose, the fasteners 91, 92 slide in the slots 71, 88, 89. After the cant is in as close a contact as practical with the deck surface 99, a roofing felt is brought from the essentially horizontal plane 99 of the deck, over the cant 80, and the main wall panel 21, to the nailer strip.13 where it is nailed in place with roofing nails 100. Then, counter flashing 101, set in the mortar of the parapet wall 97, is brought down over the nailer strip 13 and the upper edge of the felt 15.

While FIGS. 8 and 9 have been drawn to show a use of the invention in connectionn with a parapet wall, the same principles apply to all comparable installations, such as pedestals, expansion joints, and the like.

The advantages of the invention should now be apparent. The cant enables the roofing material to be applied smoothly and without sudden and abrupt angular bending. There is no need to coordinate the individual installations to specific deck structure, insulation flashing bases and deck profiles, or the like. The same curb style and structure may be used on most jobs and types of roof construction. Although the cant maybe custom fit to each installation, there is no need for installation of the cant on the job site. Moreover, each fit is as perfect as possible even if there are gross irregularities on the finished roof. Architects only need to design, draw and check one roofing detail, and minor errors in the detail specifications may be compensated.

From the foregoing, it should also be apparent that the flashing base may be cut and shaped in a single manufacturing step, then shipped to a building site in a knockdown condition. The units may be assembled on site and then the roofing material may be placed over the cant and run upwardly to the top of the curb. Moreover, the flashing may be made in almost any suitable length without requiring additional machine tooling. Also, the vertical adjustment enables the curb to have many uses. For example, it may be set on top of a wooden roof or set into a poured cement or gypsum roof. Likewise, the flashing may extend around the perimeter of the roof or it may be used as a small foot support for another device.

Accordingly, the appended claims should be construed to cover all equivalent structures falling within the scope and spirit of the invention.

I claim:

1. A process for weatherproofing a roof comprising the steps of:

a. prefabricating sheet metal flashing base in the form of a vertical member having an attached cant member movably positioned thereon,

b. shipping said prefabricated flashing base to an installation location,

c. installing said vertical member on said roof, and

d. adjusting the height of said movable cant member on the vertical member so that said cant member fills the valley of the angle between said vertical member and said roof.

2. The process of claim 1 and the added step of:

e. covering said roof with roofing material which extends from said roof over said cant and said vertical member.

3. The process of claim 1 wherein step (f) comprises the added step of shipping said prefabricated flashing base in a knockdown form.

4. The process of claim 3 wherein step (g) comprises the added step of assembling said knockdown flashing baseonsite. 

1. A process for weatherproofing a roof comprising the steps of: a. prefabricating sheet metal flashing base in the form of a vertical member having an attached cant member movably positioned thereon, b. shipping said prefabricated flashing base to an installation location, c. installing said vertical member on said roof, and d. adjusting the height of said movable cant member on the vertical member so that said cant member fills the valley of the angle between said vertical member and said roof.
 2. The process of claim 1 and the added step of: e. covering said roof with roofing material which extends from said roof over said cant and said vertical member.
 3. The process of claim 1 wherein step (f) comprises the added step of shipping said prefabricated flashing base in a knockdown form.
 4. The process of claim 3 wherein step (g) comprises the added step of assembling said knockdown flashing base on site. 